Flame resistant fabrics and garments made from same

ABSTRACT

Unique blends of fibers that incorporate synthetic cellulosic fibers to render fabrics made with such blends more durable than fabrics made with natural cellulosic fibers such as cotton. While more durable than cotton, the synthetic cellulosic fibers used in the blends are still inexpensive and comfortable to the wearer. Thus, the benefits of cotton (affordability and comfort) are still attained while a drawback of cotton—low durability—is avoided. In one embodiment, the fiber blend includes FR modacrylic fibers and synthetic cellulosic fibers, preferably, but not necessarily non-FR lyocell fibers such as TENCEL™ and TENCEL A100™. Other fibers may be added to the blend, including, but not limited to, additional types of inherently FR fibers, anti-static fibers, anti-microbial fibers, stretch fibers, and/or high tenacity fibers. The fiber blends disclosed herein may be used to form various types of FR fabrics. Desired colors may be imparted in a variety of ways and with a variety of dyes to the fabrics disclosed herein. Fabrics having the fibers blends disclosed herein can be used to construct the entirety of, or various portions of, a variety of protective garments for protecting the wearer against electrical arc flash and flames, including, but not limited to, coveralls, jumpsuits, shirts, jackets, vests, and trousers.

FIELD OF THE INVENTION

The present invention relates to protective fabrics, and morespecifically to flame resistant fabrics, having a unique blend of fibersand garments made from such fabrics.

BACKGROUND OF THE INVENTION

Many occupations can potentially expose an individual to electrical arcflash and/or flames. To avoid being injured while working in suchconditions, these individuals typically wear protective garmentsconstructed of flame resistant materials designed to protect them fromelectrical arc flash and/or flames. Such protective clothing can includevarious garments, for example, coveralls, pants, and shirts. Fabricsfrom which such garments are constructed, and consequently the resultinggarments as well, are required to pass a variety of safety and/orperformance standards, including ASTM F 1506, NFPA 2112, NFPA 70E, MIL C43829C.

Many protective garments have been made from fabrics comprising naturalcellulosic fibers, such as cotton. Cotton fibers are inexpensive andfabrics made from such fibers comfortable to wear. However, the use ofcotton fibers in such fabrics has many disadvantages. To begin, cottonfibers are not durable. Thus, fabrics made with them have poor wear lifeand must be replaced unacceptably often.

Furthermore, cotton fibers pose a health hazard to personnel during thefiber spinning and fabric weaving processes. When natural cotton fibersare used to make fabrics and garments, the cotton fibers can be inhaledand over time can cause respiratory problems, which can lead tobyssinosis or “brown lung” disease. Work environments where personnelwork with natural cotton and are exposed to breathing hazardous cottonfibers are thus subject to governmental and regulatory restrictions forhandling and processing of such fibers.

Moreover, cotton fibers are not inherently flame resistant and thus aptto burn. Thus, these fibers (or the yarns or fabrics made with suchfibers) have historically been treated with a FR compound to render suchfibers (or the yarns or fabrics made with such fibers) flame resistant.Treatment of cotton fibers (or the yarns or fabrics made with suchfibers) with an FR compound significantly increases the cost of suchfibers (or the yarns or fabrics made with such fibers).

To avoid the cost associated with such FR treatment, cotton fibers havebeen combined with FR modacrylic fibers. The FR modacrylic fiberscontrol and counteract the flammability of the cotton fibers to preventthe cotton fibers from burning. In this way, the cotton fibers (or theyarns or fabrics made with such fibers) need not be treated with a FRcompound.

However, the FR modacrylic fibers have durability problems similar tothose of cotton, and thus fabrics made with blends of these fibers havepoor wear life. Moreover, both natural cotton fibers and FR modacrylicfibers are relatively unstable after thermal exposure, rendering itdifficult if not impossible for fabrics made with only these fibers topass the requisite safety and performance standards for protectivegarments. Thus, additional inherently FR fibers, such as aramid fibers,have been added to the fiber blend to impart thermal stability to theblend to ensure compliance of the resulting fabric with the requisitesafety and performance standards (e.g., by decreasing char lengths invertical flame tests of such fabrics).

Because of the presence of cotton fibers, the resulting fabrics stillexhibit durability problems and unacceptable wear life. Thus, a needexists for fiber blends that include fibers that are more durable thannatural cellulosic fibers such as cotton but that still realize the costand comfort advantages of cotton in such blends.

SUMMARY OF THE INVENTION

This invention discloses unique blends of fibers that incorporatesynthetic cellulosic fibers to render fabrics made with such blends moredurable than fabrics made with natural cellulosic fibers such as cotton.While more durable than cotton, the synthetic cellulosic fibers used inthe blends are still inexpensive and comfortable to the wearer. Thus,the benefits of cotton (affordability and comfort) are still attainedwhile a drawback of cotton—low durability—is avoided. The resultingfabrics made with the fiber blends disclosed herein are flame resistant,durable, comfortable, and affordable.

In one embodiment, the fiber blend includes FR modacrylic fibers andsynthetic cellulosic fibers, preferably, but not necessarily non-FRlyocell fibers such as TENCEL™ and TENCEL A100™. The FR modacrylicfibers and the synthetic cellulosic fibers can be combined in any blendratio but are preferably, although not necessarily, combined so that thepercentage of FR modacrylic fibers in the blend is greater than thepercentage of synthetic cellulosic fibers in the blend. Other fibers maybe added to the blend, including, but not limited to, additional typesof inherently FR fibers, anti-static fibers, anti-microbial fibers,stretch fibers, and/or high tenacity fibers.

The fiber blends disclosed herein may be used to form various types ofFR fabrics. By way only of example, the fibers may be used to formnonwoven fabrics or may first be formed into yarn that is subsequentlywoven or knitted into a FR fabric.

In one embodiment, yarns are formed from a fiber blend havingapproximately 30-60% FR modacrylic fibers, approximately 20-60%synthetic cellulosic fibers, and approximately 5-30% additionalinherently FR fibers. TENCEL™ and particularly TENCEL A100™ (both non-FRsynthetic cellulosic fibers) and para-aramid fibers (inherently FRfibers) have performed particularly well in this application. The yarnscan subsequently be used to form FR fabrics in a variety of ways (e.g.weaving, knitting, etc.), all well known in the industry. Fabrics madefrom the unique fiber blends disclosed herein comply with a variety ofthe thermal protection standards, rendering them suitable for use inprotective garments.

Desired colors may be imparted in a variety of ways and with a varietyof dyes to the fabrics disclosed herein having a blend of syntheticcellulosic, FR modacrylic, and optionally additional inherently FRfibers. The fabrics may be dyed or printed to comply with the standardfor high-visibility safety apparel known in the industry as ANSI107-2004 (and the European equivalent EN 471) as well as with themilitary's infrared reflective requirements (including, but not limitedto, those promulgated under MIL-C-83429 and GL-PD-07-12 (Feb. 28,2007)).

Fabrics having the fibers blends disclosed herein can be used toconstruct the entirety of, or various portions of, a variety ofprotective garments for protecting the wearer against electrical arcflash and flames, including, but not limited to, coveralls, jumpsuits,shirts, jackets, vests, and trousers. In one embodiment, a fabric havingblends of fibers disclosed herein is used to form at least a portion ofan advanced combat shirt.

DETAILED DESCRIPTION OF THE INVENTION

This invention relates to unique blends of fibers that render theresulting fabric flame resistant, durable, comfortable, and affordable.In one embodiment, the fiber blend includes FR modacrylic fibers andmanmade or synthetic cellulosic fibers. The FR modacrylic fibers and thesynthetic cellulosic fibers can be combined in any blend ratio but arepreferably, although not necessarily, combined so that the percentage ofFR modacrylic fibers in the blend is greater than the percentage ofsynthetic cellulosic fibers in the blend.

Any FR modacrylic fibers able to extinguish non-FR fibers may be used,including, but not limited to, PROTEX™ fibers (including but not limitedto PROTEX W™ and PROTEX C™ fibers) available from Kaneka Corporation ofOsaka, Japan, SEF™ available from Solutia, or blends thereof. Thesynthetic cellulosic fibers may be, but are not limited to, rayon, FRrayon, lyocell, MODAL™, cellulose acetate, or blends thereof. An exampleof a suitable rayon fiber is Viscose by Lenzing, available from LenzingFibers Corporation. Examples of lyocell fibers include TENCEL™ andTENCEL A100™, both available from Lenzing Fibers Corporation. Examplesof FR rayon fibers include Lenzing FR™, also available from LenzingFibers Corporation, and VISIL™, available from Sateri.

The synthetic fibers used in the blends disclosed herein can be, butpreferably are not, FR-treated given that they are being blended with FRmodacrylic fibers that control and counteract the flammability of thesynthetic fibers to prevent such fibers from burning. Use of syntheticcellulosic fibers that have not been FR-treated significantly reducesthe cost of such fibers (e.g., approximately $1/pound for non-FR treatedsynthetic cellulosic fibers vs. approximately $6/pound for FR-treatedsynthetic cellulosic fibers).

Non-FR lyocell fibers such as TENCEL™ and TENCEL A100™ fibers haveproven to be particularly suitable in this application. While similar tocotton fibers in that these fibers are inexpensive and comfortable, theyare more durable than natural cotton fibers and have proven veryresistant to abrasion and very moisture absorbent. Consequently, fabricsmade from these fibers have long wear life and are comfortable to thewearer. TENCEL A100™ fibers are less susceptible to fibrillation, whichresults when the ends of the fibers split to impart a fuzzy orprematurely worn appearance to garments made with such fibers. It hasbeen found that fabrics made with TENCEL A100™ fibers are thus betterable to retain their appearance even after repeated launderings.Moreover, unlike natural cotton typically used in these blends, becausethese cellulosic fibers are manmade fibers, they consequently do notpose a breathing hazard to personnel during the fiber spinning or fabricfabrication process.

In an alternative embodiment, an additional type (or types) ofinherently FR fibers (i.e., in addition to the FR modacrylic fiberswhich are inherently FR) may be added to the FR modacrylic/syntheticcellulosic fiber blend. The additional inherently FR fibers may include,but do not have to include, para-aramid fibers, meta-aramid fibers,polybenzimidazole (PBI) fibers, polybenzoxazole (PBO) fibers, melaminefibers, carbon fibers, pre-oxidized acrylic fibers, polyacrylonitrile(PAN) fibers, TANLON™ (available from Shanghai Tanlon Fiber Company),polyamide-imide fibers such as KERMEL™, and blends thereof. Examples ofpara-aramid fibers include KEVLAR™ (available from DuPont), TECHNORA™(available from Teijin Twaron BV of Arnheim, Netherlands), and TWARON™(also available from Teijin Twaron BV). Examples of meta-aramid fibersinclude NOMEX™ (available from DuPont), CONEX™ (available from Teijin),and APYEIL™ (available from Unitika). An example of melamine fibers isBASOFIL™ (available from Basofil Fibers). An example of PAN fibers isPanox® (available from the SGL Group). As explained above, suchinherently FR fibers impart the requisite thermal stability to the blendto enable fabrics made from such blends to be used in protectivegarments.

In other embodiments, additional fibers, including, but not limited to(1) anti-static fibers to dissipate or minimize static, (2)anti-microbial fibers, (3) stretch fibers (e.g., spandex), and/or (4)high tenacity fibers such as, but not limited to, nylon and/or polyesterfibers (such as VECTRAN™) are added to the blends to improve the wearproperty of fabrics made with such blends.

The fiber blends disclosed herein may be used to form various types ofFR fabrics. By way only of example, the fibers may be used to formnonwoven fabrics or may first be formed into yarn that is subsequentlywoven or knitted into a FR fabric.

In one embodiment, yarns are formed from a fiber blend havingapproximately 30-60% FR modacrylic fibers, approximately 20-60%synthetic cellulosic fibers, and approximately 5-30% additionalinherently FR fibers. TENCEL™ and particularly TENCEL A100™ (both non-FRsynthetic cellulosic fibers) and para-aramid fibers (inherently FRfibers) have performed particularly well in this application. The sametypes of FR modacrylic fibers, synthetic cellulosic fibers, andadditional inherently FR fibers need not be used in the blend. Rather,multiple types of each may be blended together.

The yarns can be formed in conventional ways well known in the industry.The yarns may be spun yarns and can comprise a single yarn or two ormore individual yarns that are twisted, or otherwise combined, together.In one embodiment, the yarns are air jet spun yarns. Typically, theyarns comprise one or more yarns that each have a yarn count in therange of approximately 5 to 60 cc. In one embodiment, the yarns comprisetwo yarns that are twisted together, each having a yarn count in therange of approximately 10 to 60 cc.

The yarns can subsequently be used to form FR fabrics in a variety ofways, all well known in the industry. The yarns can be knitted or woven.In one embodiment, the FR fabric is formed as a plain weave fabric thatcomprises a plurality of body yarns. However, it will be appreciatedthat other configurations could be used including, for instance, arip-stop or a twill weave such as a 2×1 right hand twill weave.

Regardless of the manner by which the FR fabric is formed (nonwoven,knitted, woven, etc.), the FR fabric can be made from a blend of fibersthat includes having approximately 30-60% FR modacrylic fibers,approximately 20-60% synthetic cellulosic fibers (preferably, but notnecessarily, TENCEL™ fibers and more preferably TENCEL A100™ fibers) andapproximately 5-30% additional inherently FR fibers (preferably, but notnecessarily, para-aramid fibers). As discussed above, the FR fabric mayinclude a fiber blend that includes anti-static, anti-microbial,stretch, and/or high tenacity fibers.

In a much more specific example that is certainly not intended to limitthe scope of the invention discussed herein, the FR fabric includes ablend of between approximately 40-50% FR modacrylic fibers,approximately 30-40% synthetic cellulosic fibers (preferably, but notnecessarily, TENCEL™ fibers and more preferably TENCEL A100™ fibers),and approximately 10-15% aramid fibers (preferably, but not necessarily,para-aramid fibers).

The FR fabrics formed with the blends disclosed herein preferably, butnot necessarily, have a weight between approximately 3-12 ounces persquare yard (“osy”) and more preferably between approximately 5-9 osy.

Specific examples of embodiments of fabrics in accordance with theinvention are described as follows.

Fabric Blend #1: One embodiment of the invention is a fabric with ablend of approximately 50% PROTEX W™ (FR modacrylic), approximately 40%TENCEL A100™ (cellulosic), and approximately 10% TWARON™ (para-aramid).

Fabric Blend #2: Another embodiment of the invention is a fabric with ablend of approximately 45% PROTEX W™ (FR modacrylic), approximately 35%TENCEL A100™ (cellulosic), approximately 10% Lenzing FR™ or FR rayon(cellulosic), and 10% TWARON™ (para-aramid).

Fabric Blend #3: Another embodiment of the invention is a fabric with ablend of approximately 50% PROTEX W™ (FR modacrylic), approximately 35%TENCEL A100™ (cellulosic), approximately 10% nylon, and approximately 5%TWARON™ (para-aramid).

Fabric Blend #4: Another embodiment of the invention is a fabric with ablend of approximately 48% PROTEX W™ (FR modacrylic), approximately 37%TENCEL A100™ (cellulosic), and approximately 15% TWARON™ (para-aramid).

As evidenced in Table 1, FR fabrics made from the unique fiber blendsdisclosed herein comply with the before-wash vertical flammabilityrequirements set forth in ASTM F 1506 and NFPA 70E, including havingacceptable arc thermal protective values (“ATPV”). Workers who may beexposed to accidental electric arc flash risk serious burn injury unlessthey are properly protected. NFPA 70E is the standard that addresseselectrical safety requirements, providing information on all aspects ofelectrical safety in the workplace. NFPA 70E offers a method to matchprotective clothing to potential exposure levels incorporating HazardRisk Categories (HRC). Protective fabrics are tested to determine theirATPV or arc rating in cal/cm² (calories per square centimeter). The ATPVis determined by ASTM test method F 1959, where sensors measure thermalenergy properties of protective fabric specimens during exposure to aseries of electric arcs. The measured arc rating determines the HRC fora fabric as follows:

Hazard Risk Category and ATPV

-   -   HRC 1: ATPV: 4 cal/cm²    -   HRC 2: ATPV: 8 cal/cm²    -   HRC 3: ATPV: 25 cal/cm²    -   HRC 4: ATPV: 40 cal/cm²

In addition to complying with ASTM F 1506 and NFPA 70E as discussedabove, Fabric Blends #2-#4 comply with the before-wash verticalflammability requirements set forth in ASTM 2112, including havingacceptable char lengths (as measured with the testing method set forthin ASTM 6413).

TABLE 1 Fabric Weight Char length Ratio of (ounces per square (inches)ATPV ATPV to Fabric Blend yard or “osy”) warp × fill (cal/cm²) WeightFabric Blend #1 9.3 4.2 × 3.5 8.8 0.95 Fabric Blend #2 8.4 3.1 × 2.8 8.20.97 Fabric Blend #3 8.6 3.3 × 2.3 6.8 0.79 Fabric Blend #4 8.4 3.3 ×2.6 9.3 1.10 Fabric Blend #4 7.6 3.5 × 2.7 8.4 1.11

Fabrics made from the fiber blends contemplated in this application alsohave surprisingly high resistances to abrasion. As explained above,TENCEL™ and TENCEL A100™ fibers are very durable fibers. It is notsurprising, therefore, that Taber abrasion test results of fabrics madefrom fiber blends having such fibers indicate substantially highresistance to abrasion—indeed almost as high as fabrics made from 100%inherently FR fibers and higher than fabrics made with other fiberblends that comply with the ASTM F 1506, NFPA 2112, and NFPA 70Estandards. Moreover, while abrasion resistance is high, the inclusion ofmodacrylic and cellulosic fibers in the blends contemplated hereinrender the resulting fabric soft and thus more comfortable to thewearer.

Desired colors may be imparted in a variety of ways to the fabricsdisclosed herein having a blend of synthetic cellulosic, FR modacrylic,and optionally additional inherently FR fibers. In one embodiment, thesynthetic cellulosic fibers and/or modacrylic fibers are dyed (eitherprior to their formation into yarn, after formation into yarns, or inthe final fabric). The synthetic cellulosic and/or modacrylic fibers maybe dyed any of a variety of colors, including, but not limited to,yellow, fluorescent yellow, green, orange, red, blue, gray, etc. usingthe dyes (or combinations of dyes) disclosed herein.

Dyeing may be achieved using a variety of well-known techniques,including exhaust dyeing processes using a jet, beam, beck, or jigdyeing apparatus or continuous dyeing processes, all of which are wellknown in the art. Suitable dyes for dyeing the modacrylic fibersinclude, but are not limited to, basic dyes and disperse dyes. Suitabledyes for dyeing the synthetic cellulosic fibers include, but are notlimited to, fiber reactive dyes, direct dyes, and vat dyes.

In one embodiment, the fabrics are dyed to comply with the standard forhigh-visibility safety apparel known in the industry as ANSI 107-2004and the European equivalent EN 471. To comply with ANSI 107-2004, afabric must (1) be dyed to a high-visibility shade (measured byreference to a fabric's chromaticity and luminance) and (2) maintainthat high-visibility shade after being subjected to light for aspecified period of time (an attribute referred to in the standard as“light fastness”). The dyes for each of the synthetic cellulosic fibersand the modacrylic fibers are thus selected so as to achieve dyeing ofthese fibers to a high-visibility shade. Dyes that enable dyeing of thesynthetic cellulosic fibers to a high-visibility shade include, but arenot limited to, direct dyes (including, but not limited to, DirectYellow 96) and fiber reactive dyes (including, but not limited to,Remazol Luminous Yellow FL). Dyes that enable dyeing of the FRmodacrylic fibers to a high-visibility shade include, but are notlimited to, basic dyes such as Basic Yellow 40.

In one example, the FR modacrylic fibers and the synthetic cellulosicfibers of fabrics having Fabric Blends #1-4 (disclosed above) as well asan additional fabric blend (Fabric Blend #5 having approximately 50%PROTEX W™ (FR modacrylic), approximately 39% TENCEL A100™ (cellulosic),approximately 10% TWARON™ (para-aramid), and approximately 1% antistat))were dyed in accordance with a two-step exhaust dyeing process usingBasic Yellow 40 to dye the FR modacrylic fibers and Remazol LuminousYellow FL to dye the TENCEL A100™ fibers. The results are set forthbelow in Table 2.

TABLE 2 % Basic % Remazol Salt Pass Yellow 40 Yellow FL Alkali (SodiumANSI FABRIC BLEND Dye (owf) Dye (owf) (Soda Ash) Caustic Sulphate)107-2004? Fabric Blend # 1 1.20 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 1 1.20 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 1 2.25 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 1 2.25 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 2 1.20 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 2 1.20 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 2 2.25 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 2 2.25 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 3 1.20 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 3 1.20 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 3 2.25 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 3 2.25 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 4 1.20 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 4 1.20 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 4 2.25 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 4 2.25 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 5 1.20 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 5 1.20 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 5 2.25 3.85 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%) Fabric Blend # 5 2.25 5.00 5.00 g/L/1.292 80 g/L Yesg/L(NaOH50%)

Fabrics having the FR modacrylic/synthetic cellulosic blends (andparticularly those using TENCEL™ and TENCEL A100™ fibers) may be dyed incompliance with the military's infrared reflective requirements(including, but not limited to, those promulgated under MIL-C-83429 andGL-PD-07-12 (Feb. 28, 2007)). Vat dyes have proven particularly suitablefor dyeing the fabrics in compliance with such standards. Vat dyeingtechniques, such as, but not limited to, those disclosed in TextileDyeing and Coloration by J. R. Aspland (Chapters 4: Vat Dyes: Generaland 5: Vat Dyes and their Application), are well known in the art andthus not discussed in detail herein. The fabrics disclosed herein mayalso be printed with dyes or pigments. For example, such fabrics may beprinted in compliance with the military's infrared reflectiverequirements with vat dyes using printing techniques well known in theart.

After all dyeing has been completed, the fabric then can be finished inconventional manner. This finishing process can include the applicationof FR treatments, anti-microbial agents, insect repellent agents,pesticides, soil release agents, wicking agents, water repellents (e.g.,perfluorohydrocarbon), stiffening agents, softeners, and the like.

Fabrics having the fiber blends disclosed herein can be used toconstruct the entirety of, or various portions of, a variety ofprotective garments for protecting the wearer against electrical arcflash and flames, including, but not limited to, coveralls, jumpsuits,shirts, jackets, vests, and trousers. Retroreflective elements, such asstrips of retroreflective tape, may be provided on portions of theexterior of the garments to enhance the visibility of the garmentwearer.

In one embodiment, a fabric having blends of fibers disclosed herein isused to form at least a portion of an advanced combat shirt. Advancecombat shirts are worn under bullet proof vests. When a bullet proofvest is positioned over the shirt, the shoulders and sleeves of theshirt typically remain exposed but the body portion of the shirt issubstantially covered by the vest. Thus, the shoulders and sleeves ofthe shirt have traditionally been made from woven or heavy weight knitFR fabrics (such as those disclosed in U.S. Pat. No. 6,867,154, theentirety of which is herein incorporated by reference) that protect thewearer against flame and radiant energy and are typically printed (suchas with a camouflage pattern) to ensure the wearer does not stand out inhis or her surrounding environment.

Because the body portion of the shirt is concealed by the bullet proofvest which protects the wearer's torso, it need not be made from thesame materials or afford the same level of FR protection to the wearer.The inventors have discovered that forming the body portion of the shirtfrom an FR fabric having a blend that includes FR modacrylic andsynthetic cellulosic fibers results in a shirt with better wearproperties that is more comfortable to the wearer. In one embodiment,the body portion of the shirt is formed of a 50/50 blend of FRmodacrylic fibers and synthetic cellulosic fibers (suitable examples ofeach of which are identified in the discussion above).

The blend need not only include FR modacrylic and synthetic cellulosicfibers, however. Rather, other fibers may be added to the blend,including, but not limited to, additional inherently FR fibers (suitableexamples of which are identified in the discussion above), polyesterfibers, nylon fibers, or fibers that impart stretchability to theresulting fabric (e.g., spandex). In an alternative embodiment, thefiber blend includes between approximately 30-60% FR modacrylic fibers,approximately 20-60% synthetic cellulosic fibers, approximately 5-30%additional inherently FR fibers, and between 5-25% nylon fibers. In amore specific embodiment, the fiber blend includes approximately 50%modacrylic fibers (and preferably, but not necessarily, PROTEX W™fibers), 30% lyocell fibers (and preferably, but not necessarily, TENCELA100™ fibers), 10% para-aramid fibers (and preferably, but notnecessarily, TWARON™ fibers), and 10% nylon fibers.

The fiber blend is formed into yarns that is then used to form thefabric for use in the body portion of the shirt. While any type of yarnmay be formed, spun yarns are particularly suitable in this applicationgiven their high absorptive properties. It has been found that a fabricprovided with apertures (i.e., a mesh fabric) is particularlywell-suited in this application because the resulting mesh fabric isbreathable and allows air to circulate under the vest and thus keeps thewearer cool. The mesh fabric may be formed in a variety of ways, withknitting, and particularly circular knitting, being particularlysuitable.

Any portion of the shirt may be formed from the mesh material. Dependingon the stretchability of the mesh, it may be desirable to incorporatestretchable panels of FR fabric into the shirt (such as in side panelsof the shirt) for ease of donning and removing the garment by thewearer. The stretchable panels may be formed of any FR fabric,including, but not limited to, the fabrics contemplated herein.

The foregoing is provided for purposes of illustrating, explaining, anddescribing embodiments of the present invention. Further modificationsand adaptations to these embodiments will be apparent to those skilledin the art and may be made without departing from the scope or spirit ofthe invention.

1-33. (canceled)
 34. A woven or knitted single-layer flame resistantfabric comprising a fiber blend comprising: a. a first percentage ofmodacrylic fibers in the fiber blend, wherein the first percentage isless than forty percent; b. a second percentage of non-flame resistantmanmade cellulosic fibers in the fiber blend; and c. a third percentageof nylon in the fiber blend, wherein the fabric has an afterflame lessthan 2 seconds when tested according to ASTM Test D6413.
 35. The flameresistant fabric of claim 34, wherein the second percentage is notgreater than the first percentage.
 36. The flame resistant fabric ofclaim 34, wherein the sum of the second and third percentages is greaterthan the first percentage.
 37. The flame resistant fabric of claim 34,wherein the third percentage comprises at least 25% of the fiber blend.38. The flame resistant fabric of claim 34, wherein the fiber blend isdevoid of aramid fibers.
 39. The fabric of claim 34, wherein the fabrichas a before-wash char length less than or equal to 4 inches when testedaccording to ASTM Test D6413.
 40. The fabric of claim 34, wherein thefabric complies with at least one of ANSI 107-2004, NFPA 2112, and NFPA70E.
 41. The fabric of claim 34, wherein the fabric comprises an arcthermal protection value when tested according to ASTM Test F1959 andwherein the ratio of the arc thermal protection value to the weight isat least 1.05.
 42. A single layer woven or knitted flame resistantfabric for garments comprising a fiber blend, wherein: i. the fiberblend comprises modacrylic fibers, non-flame resistant lyocell fibers,and aramid fibers; ii. the aramid fibers constitute at least 10% of thefiber blend; iii. the lyocell fibers constitute greater than 30% and nomore than 50% of the fiber blend; iv. the modacrylic fibers constituteat least 40% and less than 60% of the fiber blend; and v. the fabric hasa fabric weight greater than 3 ounces per square yard (osy) and lessthan 7.8 osy.
 43. The fabric of claim 42, wherein the aramid fibersconstitute more than 10% of the fiber blend.
 44. The fabric of claim 42,wherein the fabric weight is 7.5 osy or less.
 45. The fabric of claim44, wherein the fabric weight is 7 osy or less.
 46. The fabric of claim45, wherein the fabric weight is 6.5 osy or less.
 47. The fabric ofclaim 42, wherein the fabric has a before-wash char length of less thanor equal to 4 inches when tested according to ASTM Test D6413.
 48. Thefabric of claim 47, wherein the fabric has a before-wash char length ofless than or equal to 3.5 inches when tested according to ASTM TestD6413.
 49. The fabric of claim 48, wherein the fabric has a before-washchar length of less than or equal to 3 inches when tested according toASTM Test D6413.
 50. The fabric of claim 49, wherein the fabric has abefore-wash char length of less than or equal to 2.5 inches when testedaccording to ASTM Test D6413.
 51. A single layer woven or knitted flameresistant fabric comprising a fiber blend, wherein the fiber blendcomprises modacrylic fibers and a plurality of non-flame resistantsynthetic cellulosic fibers, wherein the fabric is capable of complyingwith ANSI 107-2004 and NFPA
 2112. 52. The fabric of claim 51, whereinthe modacrylic fibers comprise a first percentage of the fiber blend andthe synthetic cellulosic fibers comprise a second percentage of thefiber blend, wherein the first percentage is greater than the secondpercentage.
 53. The fabric of claim 51, wherein the fiber blend furthercomprises aramid fibers.
 54. The fabric of claim 53, wherein the aramidfibers constitute at least 10% of the fiber blend.
 55. The fabric ofclaim 54, wherein the aramid fibers constitute more than 10% of thefiber blend.
 56. The fabric of claim 53, wherein the aramid fiberscomprise para-aramid fibers.
 57. The fabric of claim 51, wherein thefabric has a fabric weight greater than 3 ounces per square yard (osy)and less than 7.8 osy.
 58. The fabric of claim 57, wherein the fabricweight is 7.5 osy or less.
 59. The fabric of claim 58, wherein thefabric weight is 7 osy or less.
 60. The fabric of claim 59, wherein thefabric weight is 6.5 osy or less.
 61. The fabric of claim 51, whereinthe fabric has a before-wash char length of less than or equal to 4inches when tested according to ASTM Test D6413.
 62. The fabric of claim61, wherein the fabric has a before-wash char length of less than orequal to 3.5 inches when tested according to ASTM Test D6413.
 63. Thefabric of claim 62, wherein the fabric has a before-wash char length ofless than or equal to 3 inches when tested according to ASTM Test D6413.